Fuel Sender Assembly Replacement Utility/Crew Cab

Tools Required

J 44402 Fuel Tank Sending Unit Wrench

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the fuel tank. Refer to Fuel Tank Replacement .

Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

3. Remove the fuel sender assembly retaining ring using theJ 44402 .
4. Remove the fuel sender assembly and the seal. Discard the seal.

Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

5. Clean the fuel sender sealing surfaces.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Install the new seal on the fuel tank.

Important: The fuel strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel strainer does not block full travel of the float arm.

2. Install the fuel sender assembly into the fuel tank.
3. Install the fuel sender assembly retaining ring using theJ 44402 .
4. Install the fuel tank. Refer to Fuel Tank Replacement .
5. Refill the fuel tank.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.

8.1.	Turn ON the ignition for 2 seconds.

8.2.	Turn OFF the ignition for 10 seconds.

8.3.	Turn ON the ignition.

8.4.	Inspect for fuel leaks.

Fuel Sender Assembly Replacement Pick-Up

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Remove the pickup box. Refer to Pickup Box Replacement in Body Rear End.
4. Disconnect the fuel sender electrical connectors.
5. Disconnect the fuel sender fuel and evaporative emission (EVAP) pipes.




Important: 

•	The modular fuel sender assembly may spring up from the fuel tank.

•	When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The fuel sender assembly must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.

•	Carefully discard the reservoir fuel into an approved container.

6. While holding the modular fuel sender assembly down, remove the snap ring from designated slots (1) located on the retainer.

1. Install a new O-ring on the modular fuel sender to the tank.
2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.

Important: Ensure that the snap ring is fully seated within the tab slots.

4. Insert snap ring into designated slots (1).
5. Connect the fuel sender fuel and EVAP pipes.
6. Connect the fuel sender electrical connectors.
7. Connect the negative battery cable.
8. Inspect for fuel leaks through the following steps:

8.1.	Turn ON the ignition for 2 seconds.

8.2.	Turn OFF the ignition for 10 seconds.

8.3.	Turn ON the ignition.

8.4.	Inspect for fuel leaks.

9. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.